Adhesive Application on Moving Web via Pulsed Nozzle Control
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Solution Overview
Problem
Existing adhesive application methods for moving webs face challenges in controlling adhesive placement and quantity, especially at high speeds, leading to collateral spray, adhesive strength issues, and inefficiencies in adhesive application.
Innovation Solution
A system and process that utilize an adhesive control device to enable and disable adhesive flow through a nozzle before and during contact with the moving web, combined with a web deflecting device to control web tension and contact angle, allowing for precise adhesive application and self-cleaning of the nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesive is sprayed using conventional pressure-based techniques, then adhesive can be applied to the moving web, but control over adhesive placement and quantity is difficult
Solution Approach 1:
The system pre-pressurizes the adhesive reservoir before adhesive application, ensuring consistent adhesive flow pressure is established in advance. This preliminary pressurization action allows for better control of adhesive quantity and placement during the actual application process, resolving the contradiction between precision and complexity.
2Productivity
If adhesive is applied at high web speeds, then productivity increases, but adhesive application length increases causing material waste
Solution Approach 1:
The system employs periodic pulsed spray action where adhesive is delivered in controlled intervals rather than continuously. The controller activates the spray valve only during specific time windows when the web is in the optimal position, creating periodic adhesive application cycles. This allows high web speeds to be maintained while minimizing adhesive application length and material waste.
Solution Approach 2:
The system uses a controller that monitors web position and timing to regulate adhesive spray activation. This feedback mechanism ensures adhesive is applied only when needed at the correct location, preventing excessive adhesive application length even at high web speeds, thus reducing material waste while maintaining productivity.
3Strength
If adhesive spray pressure is increased to improve adhesive strength, then bonding improves, but collateral spray increases
Solution Approach 1:
The system uses individual controllable spray nozzles that can be selectively activated based on local requirements. Each nozzle or group of nozzles can be independently controlled to spray adhesive only where needed on the web. This localized spray approach maintains adequate adhesive strength at target locations while minimizing collateral spray to surrounding areas.
4Loss of substance
If web speed is decreased to reduce adhesive streak length, then material waste decreases, but productivity decreases
Solution Approach 1:
The system uses periodic pulsed spray action synchronized with web movement, delivering adhesive in short controlled bursts rather than continuous streams. This allows the web to move at high speeds while adhesive is applied only during brief intervals, creating short adhesive streaks and minimizing material waste without reducing productivity.
Data Source
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AI summary
A system and process are disclosed for applying an adhesive composition to a moving web of material. During the process, a web of material is conveyed very rapidly adjacent to a nozzle of an adhesive applicator. A defecting device periodically deflects the web into contact with a surface of the nozzle. An adhesive flow control device is used to control the flow of adhesive through the nozzle. Adhesive flows through the nozzle and is timed with the deflection device. In one embodiment, the flow of adhesive is started prior to contact with the web. In this manner, treated discrete areas of the adhesive composition can be formed on the web. The treated discrete areas can have lengths that are minimized through the process of the present disclosure allowing for adhesive to be applied at extremely fast speeds.